Wireless Ultrasonic Flow Meter for Manual Valve Actuation Control
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Solution Overview
Problem
Manually operated valves in piping circuits often lead to accidental fluid flow, causing damage and increased costs due to poor accuracy in flowrate measurement, especially since conventional flowmeters are costly and impractical for all circuits.
Innovation Solution
A system using a removable ultrasonic wireless flow meter and a control system that determines the optimum time and speed to actuate manually operated valves based on predictive models, eliminating the need for hardware flowmeters and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional flowmeters are installed in all piping circuits, then flowrate measurement accuracy is improved, but capital expense and operating expense are greatly increased
Solution Approach 1:
The patent replaces conventional mechanical flowmeters with an ultrasonic flow measurement system that uses acoustic waves to measure fluid velocity. The ultrasonic transmitters and receivers emit and detect sound waves through the fluid, calculating flowrate based on the time difference of wave propagation with and against the flow. This substitution eliminates moving parts and mechanical components, reducing maintenance requirements and capital costs while maintaining measurement accuracy.
Solution Approach 2:
The patent uses ultrasonic transmitters and receivers that create acoustic copies or representations of the fluid flow characteristics. By measuring the speed of sound waves traveling through the fluid in different directions, the system creates a virtual model of flow velocity and calculates flowrate without physically obstructing or contacting the fluid stream, thereby avoiding the need for intrusive mechanical flowmeters.
2Measurement precision
If conventional flowmeters are installed, then flowrate measurement capability is improved, but maintenance time and non-productive operations are increased
Solution Approach 1:
The ultrasonic flow measurement system replaces mechanical flowmeters with no moving parts, eliminating wear and tear issues. The solid-state ultrasonic transmitters and receivers require minimal maintenance, typically only periodic cleaning of the external sensors and verification of calibration, significantly reducing maintenance time and non-productive operations compared to mechanical flowmeters that require preventive maintenance, obsolescence replacement, and inspection.
Solution Approach 2:
The ultrasonic flow measurement system is designed to be self-diagnosing and self-calibrating to the extent possible. The system continuously monitors its own performance parameters and can automatically compensate for certain drift conditions, reducing the frequency and duration of maintenance interventions required while maintaining measurement capability.
3Productivity
If manually operated valves are operated quickly during shutdown and startup, then productivity is improved, but piping circuit damage and catastrophic failures are increased
Solution Approach 1:
The patent implements a control system that continuously receives real-time flowrate data from the ultrasonic flow measurement system and provides feedback to operators or automated control. The system compares measured flowrate against predetermined thresholds and triggers warnings or automatic valve modulation when flowrate exceeds safe limits, enabling operators to slow down valve operation before dangerous flux occurs. This closed-loop feedback allows rapid operation when safe while preventing catastrophic failures.
Solution Approach 2:
The control system is configured with predetermined flowrate thresholds and safety criteria established before operation. When the system detects approach to dangerous flow conditions, it issues advance warnings to operators to slow valve operation before the harmful flux occurs. This preliminary action allows operators to take corrective措施 before catastrophic damage can occur, enabling both speed and safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution improves operational efficiency, reduces maintenance and operating expenses, and prevents fluid fluctuations, thereby minimizing damage and production losses.
Implementation Method 1
a removable ultrasonic wireless flow meter coupled to piping downstream from the manually operated valve
Data Source
AI summary
A system includes upstream process equipment and downstream process equipment. The upstream process equipment is configured to transmit a predetermined fluid to the downstream process equipment. A manually operated valve fluidly couples the upstream process equipment to the downstream process equipment. A removable ultrasonic wireless flow meter is coupled to piping downstream from the manually operated valve. A control system is coupled to the manually operated valve and the removable ultrasonic wireless flow meter. The control system determines an optimum time and speed to actuate the manually operated valve using a predictive model based on a valve size of the manually operated valve, a valve age of the manually operated valve, fluid type, a criticality index of the manually operated valve, a measured flow rate from the removable ultrasonic wireless flow meter, and corresponding coefficients.